Part Nine progress of Skylon concept has also impressed the European Space Agency (ESA),
which audited Reaction Engines' designs last year and found no technical
impediments to building the craft.
The bigger challenge may be securing
funding. While ESA and the British government have invested a combined $92
million in the project, Bond and his crew plan to turn to public and private
investors for the remaining $3.6 billion necessary to complete the engine,
which they say could be ready for flight tests in the next four years. Building
the craft itself would require a much heftier investment: $14 billion.The quest
for a single-stage-to-orbit spaceship, or SSTO, has bedeviled aerospace
engineers for decades. Bond's own exploration of the topic began in the early
1980s, when he was a young engineer working with Rolls-Royce as part of a team
tasked with developing a reusable spacecraft for British Aerospace.
That's when
he came up with the idea of a hybrid engine. But the team struggled to figure
out how to cool the engine at supersonic speeds without adding crippling
amounts of weight. "By the time the plane hits Mach 2 or so, the air
becomes very hot and extremely difficult to compress," Bond says.
Rolls-Royce and the British government, doubtful that an easy and economical
solution existed, canceled the program's funding.
NASA and Lockheed Martin,
meanwhile, had their own plans for a fully reusable spacecraft, this venture-star intended as an affordable replacement for the partially reusable
space shuttle here at space cruising the design within heat exchanges could have lead to a smooth transition with seebeck effect allowing higher octane mixture out to the lux.
The company venture star demonstrator, called X-33
(which graced the
cover of this magazine in 1996), was a squat, triangular rocket that would take
off vertically and glide back to Earth just as the shuttle did. Eliminating the
expendable rockets needed to boost the shuttle into space could theoretically
reduce the cost of launches from $10,000 per pound to $1,000 per pound. But by
2001, after sinking more than $1 billion into the project, the agency 'pulled
the plug', citing repeated technical setbacks and ballooning costs. "We
backed off because we felt it was better to focus our efforts on other, less
costly ways to get payloads to orbit," says Dan Dumbacher, As NASA's deputy
associate administrator for exploration systems development, who spent two
years working on the X-33. Skylon new concept air traves at Mach 5 enters the engine and passes through a heat ex-changer There, a network of paper-thin metal tubes filled with liquid helium
chill the 2,000F air to –238F almost instantly.



The company venture star demonstrator, called X-33


But for routine missions to the ISS, or to park a small observational
satellite in orbit, affordability becomes a critical consideration.
SpaceX CEO
Elon Musk told an audience at the National Press Club in 2011 that private
spaceflights would need to follow a model closer to that of airlines. "If
planes were not reusable, very few people would fly," he said. SpaceX
plans to make rocket stages reusable, but there are drawbacks to that, too:
While it is possible to recover rocket stages, designing bits and pieces to
survive reentry in good working order adds a level of complexity and cost. Hempsell
says Skylon could potentially make 100 flights annually—which, if true, could
in its first year recoup the money spent in R&D and construction, leaving
only expenses like fuel, maintenance, and overhead. And Bond's engine
technology, aside from keeping a launch vehicle intact from start to finish,
offers another advantage: supersonic aviation. "It could enable an
aircraft to fly anywhere in the world in under four hours," says Bond. When
air strikes an engine at five times the speed of sound, it can heat up to
nearly 2,000 degrees Fahrenheit. Bleeding off that heat instantly, before the
air reaches the turbo compressor and then the thrust chamber, was the most
onerous technical challenge for Reaction Engines engineers. Bond's solution is
a heat exchanger that works by running cold liquid helium through an array of
tubes with paper-thin metal walls. As the scorching-hot air moves through the
exchanger, the chilled tubing absorbs the energy, cooling the air to minus 238
degrees Fahrenheit in a fraction of a second. Bond says his exchanger could
handle about 400 megawatts of heat (equivalent to a medium-size natural-gas
plant). "If it were in a power station, it would probably be a 200-ton heat
exchanger," he says. "The one we've built is about 1.4 tons." For
rocket scientists, nothing matters more than weight. "Each pound you put
into orbit requires about 10 pounds or so of fuel to get it there," says
NASA's Dumbacher. "The challenge with the SSTO has always been to get the
craft as light as possible and generate as much thrust as possible."
Bond estimates that Skylon would weigh about 358 tons at takeoff and hold
enough hydrogen fuel to carry itself and about 16.5 tons of payload—about the
same capacity as most operational rockets—into orbit. If and when the engine
passes flight tests, one of Reaction Engines' plans is to license the
technology to a potential partner in the aerospace industry. Bond hopes the
recent success of the heat exchanger will inspire interest. After 30 years of
research, it has certainly inspired him. "It represents a fundamental
breakthrough in propulsion technology," he says. "This is the
proudest moment of my life.

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